Plastic Welding Bead Elimination in Window Frames
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Solution Overview
Problem
Existing methods for welding plastic profiled rods to form window frames result in unwanted weld beads on visible surfaces, requiring additional operations to remove them, which increase manufacturing time and lead to a rougher surface prone to dirt deposition, and are not effective for all cross sections and plastics.
Innovation Solution
The method involves pressing the outer weld beads inward by 0.5 to 1.5 mm on the visible surfaces of the window frame, removing them along with inner beads, and then joining the connecting surfaces of the profiled rods, creating an oblique edge and eliminating visible beads, suitable for all cross sections and plastics used in window frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the connecting surfaces are pressed against the welding plate and then against each other to form weld beads, then the profiled rods are joined together, but unwanted sharp-edged weld beads are formed on the visible surfaces
Solution Approach 1:
The method performs preliminary pressing of the outer weld beads inward before the final welding step. This preliminary action deforms the beads to a less prominent position, and then during the subsequent welding operation, the beads are further deformed and integrated into the joint, eliminating the need for separate removal operations while maintaining joint strength
Solution Approach 2:
The method changes the physical state and position of the weld beads through controlled deformation. By applying pressure to press the beads inward and then reheating them, the material undergoes phase changes and deformation that transform the sharp-edged beads into smoother transitions on the visible surfaces
2Shape
If special blades and milling devices are used to remove visible weld beads, then the appearance is improved, but the manufacturing time increases and additional devices are required
Solution Approach 1:
The method merges the weld bead deformation and removal function into the existing welding operation itself. By pressing the beads inward during or before the welding process, the same welding device performs both the joining and the aesthetic finishing, eliminating the need for separate removal devices and operations
Solution Approach 2:
The welding process itself is used to eliminate the weld beads through pressing and reheating. The system uses its own heating and pressing capabilities to deform and remove the beads, making the welding device self-sufficient for both joining and surface finishing without requiring external removal equipment
3Shape
If the weld beads are removed by additional operations, then the visible surfaces are improved, but the surface becomes rougher and more prone to dirt deposition
Solution Approach 1:
The method changes the physical state of the weld bead material through reheating after pressing. This thermal treatment allows the deformed bead material to flow and smooth out, creating a surface that is both aesthetically pleasing and resistant to dirt accumulation, rather than leaving rough removed surfaces
4Shape
If the known method of pressing outer beads inward and reheating is used, then some visible weld beads are reduced, but it does not work with all cross sections and plastics
Solution Approach 1:
The method is designed to be universally applicable to all cross sections and plastic materials used in window frames. The combination of pressing and reheating creates a flexible process that can accommodate different material properties and profile geometries, making the welding device versatile for various applications without requiring material-specific adjustments
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the visual appearance of the window frame by eliminating beads on visible surfaces, reducing manufacturing time, and ensuring a smoother surface without additional operations.
Implementation Method 1
the two profiled rods, which are approximately 3 mm longer at each end than the dimensions of the finished window frame, are first aligned with one another and secured in a position in which the two connecting surfaces are held far enough apart from one another that the welding plate heated to the predetermined temperature can be inserted between them. Then the connecting surfaces of the two profiled rods are pressed against the welding plate and melted
Implementation Method 2
Next, the heated connecting surfaces of the two profiled rods are again pressed against one another, whereupon the mentioned weld bead is enlarged, while the length of the profiled rods is further shortened by approximately 1 mm at the same time
Data Source
AI summary
A method for welding two hollow profiled rods made of plastic to form a window frame. The profiled rods to be joined together are heated to a predetermined temperature by inserting a welding plate between their connecting surfaces and pressing the same against the welding plate, forming outer and inner beads, and the profiled rods are pressed together under pressure after removing the welding plate, with a simultaneous increase in the size of the weld bead. For all cross sections of the profiled rods and the plastics used for manufacturing the window frames, to obtain a type of shadow groove on the top side and/or front side and on the bottom side and/or rear side of the finished window frame in the area of or near the connecting sites of the finished window frame, only the outer beads formed on the visible surface of the subsequent window frame in the area of or near the connecting sites of the two profiled rods are pressed slightly inward after removing the welding plate forming an oblique edge, and then are removed together with the inner beads, and then the connecting surfaces of the two profiled rods are joined together.